I have a 2016 Limited and when I first got the bike the gas cap was near impossible to get back into the Hole...took it in and they said they were having a lot of issues with that and gave me a new gas cap...it's been really hot the last month and now that cap is having the same problem...I think something is wrong with the plastic and it's expanding with the heat...I'll hit a different dealer and see what they say...

 

Since the original Harley gas cap is made in Mexico, shocking right?, not really, after the second warranty replacement cap in 2 years acted up again, even after filing down the bottom rim of the threaded area, I got a Stant gas cap from Walmart for $3.96 and so far it works great. The Stant cap is made in the USA but time will tell if it is better. But since my bike is out of warranty, I figured for $4.00, what the heck. I did notice that the threaded part of the Stant cap is white vs the black threaded area of the Harley cap. Maybe it's a different plastic? Or maybe Harley just has it made for them with black threads to match the top.

 

I have a 2016 road glide ultra CVO and the gas cap is also getting very hard to screw back in . I better bring it in before its to late and can't get it back in after filling her up. This is not the first I have heard of this , I guess a recall is in order .

 

My '15 had the same problem. After awhile it seems to have cured itself. Nice and smooth now.

 

Rather than fix the cap problem, I would bet that H-D will make a tool to unscrew the cap and it will cost about $100.

 

I have a 2016 street glide special with the same problem, barely could get cap back on. Stopped by Harley dealer and they switched it no questions asked, didn't even write it up.

 

File a little off of the bottom extension of the cap (around the circumference), that'll fix it permanently.

Strange that the MOCO can't manage to design something as simple as a gas cap that just works normally, but there you have it.

My '94 dyna is (was) the same way. Don't look for the MoCo to actually fix this problem anytime soon!

 

The filing method works. Went to my dealership - and they were back ordered until September on gas caps.

I hope that this is the only thing that craps out on this bike when it gets hot...

 

They swapped mine right out a couple weeks ago at the dealership. Probably with one off the showroom floor.lol

 

Bought a replacement at wallmart. $3.70

Stant 10834

Works great no issues! And the best part it's made right here in the USA